Custom Bus Bars
Optimize your electrical efficiency with engineered copper and aluminum bus bars. From precision cutting and forming to final insulation, we ensure fast turnaround times and reliable performance for your switchgear and panel boards.
Why Choose Custom Bus Bars?
ShincoFab custom bus bars offer a rigid, efficient alternative to complex wiring harnesses. With global delivery capabilities, we optimize geometry for your specific enclosure to solve thermal and spatial challenges that standard cabling simply cannot.
Higher Power Density
A flat bus bar carries significantly more current than a round cable of the same cross-sectional area. This allows you to reduce the overall size of your switchgear or power distribution unit while maintaining peak conductivity.
Superior Heat Dissipation
The wide, flat surface area of a bus bar promotes natural convection and radiation. Unlike jacketed cables that trap heat, our custom bars efficiently release thermal energy, protecting sensitive components and extending system life.
Simpler Installation
Lower Maintenance Costs
With fewer reliable connection points and higher resistance to vibration, solid bus bars minimize potential points of failure. This rigidity ensures long-term stability even in harsh industrial environments.
Engineered Material Selection
Selecting the right substrate is the first step in ensuring system integrity. Whether you require maximum ampacity or are constrained by weight restrictions, we stock and machine the industry’s highest-grade alloys.
Copper Bus Bars for Maximum Conductivity
When space is tight and current demand is high, Copper is the undisputed choice. We primarily utilize C11000 Electrolytic Tough Pitch (ETP) Copper, known for its 100% IACS conductivity rating.
- Why C11000? It offers the optimal balance of electrical conductivity, thermal transfer, and ductility for complex forming operations without cracking.
- Surface Protection: To prevent oxidation and ensure low contact resistance over time, we offer Tin (bright or matte) and Silver plating.
- Compliance:Â All copper stock is fully traceable and ROHS/REACH compliant.
Aluminum Bus Bars as the Lightweight Alternative
Aluminum offers approximately 62% of the conductivity of copper but at 30% of the weight, making it ideal for mass transit, EV, and aerospace applications where every ounce counts.
- Alloy Expertise:Â We guide you in selecting the right temper.
6061-T6:Â Ideal for structural strength and straight runs.
5052-H32: Recommended for parts requiring tight bend radii and extensive forming. - Critical Processing: Aluminum forms a non-conductive oxide layer instantly. We mitigate this through rigorous surface plating (Tin/Nickel)Â and precise finishing, ensuring your connections remain conductive and corrosion-resistant.
At-a-Glance Comparison
| Feature | C110 Copper | Aluminum (6061/5052) |
|---|---|---|
| Electrical Conductivity | Highest (100% IACS) | Moderate (~60% IACS) |
| Weight | Heavy | Lightweight (70% lighter) |
| Cost | Premium | More Economical |
| Mechanical Strength | High | Medium |
| Oxidation Resistance | Good (Excellent with plating) | Requires Plating |
Surface Treatment & Part Identification
A raw metal bar is not a finished product. To ensure low contact resistance, dielectric safety, and lifetime traceability, ShincoFab applies industry-standard finishes and markings directly in-house.
Functional Finishes for Performance Insurance
We utilize advanced plating techniques to combat oxidation and maximize current transfer, critical for both copper and aluminum substrates.
- Tin Plating: The industry standard for corrosion protection on aluminum and copper. Excellent solderability and cost-effective performance.
- Silver Plating: Recommended for high-efficiency applications. Silver reduces contact resistance significantly at joints and switching points, minimizing heat generation.
- Nickel Plating: Provides superior wear resistance and durability in harsh, corrosive environments (e.g., marine or chemical applications).
- Anodizing (Aluminum only):Â Hard-coat options available for increased dissipation and structural protection (non-contact areas).
Insulation & Aesthetic Coatings
Ensure personnel safety and system organization with our dielectric coating services.
- Epoxy Powder Coating: More than just color—this provides robust electrical insulation (up to high dielectric strength) and impact resistance. Available in standard safety colors (Red, Black, Yellow) for clear phase identification (Phase A/B/C/Ground).
- Heat Shrink Sleeving: A flexible alternative for insulating complex bent bars.
- Media Blasting & Grained Finish:Â Removes tool marks and creates a uniform, non-reflective surface for exposed architectural or equipment-grade bus bars.
Permanent Identification & Traceability
A bus bar without an ID is a liability. We ensure your parts remain identifiable through assembly, installation, and field maintenance, fully compliant with MIL-STD-130Â and aerospace standards.
- Laser Marking / Etching: Permanent, abrasion-resistant marking for barcodes, QR codes, and logos. No ink to fade or chip.
- Dot Peening: Deep material indentation for rugged environments where surface paint might wear off.
- Silkscreening:Â High-contrast ink for clear, readable instructions, danger warnings, or large part numbers.
End-to-End Precision Manufacturing & Quality Assurance
We don’t just cut metal. We engineer reliability. By keeping critical fabrication, plating, and testing processes under one roof, we eliminate the risks associated with fragmented supply chains to deliver verified precision in days, not weeks.
Mastering Total Process Control In-House
From raw sheet to finished component, your bus bars move through our facility under a unified quality management system.
- Fabrication Excellence: Equipped with advanced CNC punching stations and multi-axis CNC press brakes, we execute complex geometries with repeatable precision.
- Design Review (DFM): Before metal is cut, our engineers review your files for manufacturability, suggesting minor tweaks that can improve yield and reduce costs.
- Rapid Turnaround: Because we control the queue, we offer expedited 2-3 day prototyping services. No waiting for overseas shipping containers.
Rigorous Quality Assurance Standards
Precision is a measurable data point. Our QA lab operates independently of production to ensure objective verification.
- Vision Inspection & CMM: We utilize automated vision systems and Coordinate Measuring Machines to verify dimensional accuracy down to strict ISO tolerances.
- Testing Protocols: We perform in-house dielectric testing, hardness testing, and conductivity verification to ensure electrical integrity.
- Documentation:Â Every shipment can be accompanied by First Article Inspection (FAI) reports, Material Certifications (MTRs), and Plating Certifications upon request.
Move from CAD to Part in 48 Hours with Rapid Bus Bar Prototyping
Need to verify fit and thermal performance before mass production? We offer expedited prototyping services for custom bus bars, allowing you to test your design in the real world without committing to expensive hard tooling costs upfront.
Frequently Asked Questions
Get immediate answers to your technical and purchasing inquiries. From file formats and CAD tolerances to material selection and shipping logistics, here is everything you need to know to kickstart your project.
What file formats do you accept for custom bus bar manufacturing?
We prefer DXF, DWG, or STEPÂ files for the fastest processing. If you only have a PDF or a hand sketch, our engineering team can convert it into a CAD-ready format for your approval before production begins.
What are your standard manufacturing tolerances?
We adhere to strict ISO standards. For general dimensions, our standard tolerance is typically +/- .005″ (0.13mm), but tighter tolerances are available upon request purely depending on the material thickness and tooling selected. Please specify critical dimensions in your drawing.
Which material should I choose: C110 Copper or Aluminum?
Choose C110 Electrolytic Copper (ETP) if you need maximum conductivity (100% IACS) and compact sizing. Choose Aluminum (6061/5052)Â if weight reduction and cost are your priorities (it is ~70% lighter but requires ~60% more cross-sectional area to match copper’s ampacity).
Can you handle threaded holes, hardware insertion, or complex bending?
Yes. We offer comprehensive value-added services including tapping, PEM hardware insertion, and multi-plane bending. We deliver installation-ready components, not just cut metal.
What is your typical lead time?
Standard lead time for prototypes and small batches is 2-3 business days after design approval. For high-volume production runs or complex plating requirements, we will provide a detailed timeline with your quote. Expedited services are available for urgent breakdown situations.
Is there a Minimum Order Quantity (MOQ)?
No. We treat a single prototype with the same urgency as a 10,000-unit run. We are set up to support you from R&D testing through to full-scale mass production.
Do you simulate/test designs before manufacturing?
Yes. We perform a Design for Manufacturability (DFM)Â review on every order to catch potential issues with bend radii or hole proximity. We can also provide material certifications and First Article Inspection (FAI) reports upon request.
What plating and finishing options do you offer in-house?
We offer Tin (Flash/Matte/Bright), Silver, and Nickel plating to improve conductivity and prevent oxidation. For insulation and identification, we provide epoxy powder coating (dielectric), heat shrink sleeving, and laser marking/silkscreening.
How do you package heavy bus bars to prevent shipping damage?
We understand that soft metals (copper/aluminum) scratch easily. All parts are individually wrapped, separated by protective dunnage, and crated securely to prevent bending or surface damage during transit, ensuring they arrive ready for assembly.
Start Your Bus Bar Fabrication with a Quote and DFM Review in 24 Hours
Don’t let your production line wait. Upload your bus bar drawings (DXF, DWG, STEP) or specifications today. Our engineers will optimize your design for manufacturability and provide a competitive, no-obligation quote to get your power distribution project moving immediately.
